SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

3120740 – JLG Lift – 7-39

DCBA

DCBA

EGO 2

EGO 1BLK/LT GRN

DR GRN/WHTPNK/DK GRN

4321

BOSCHTMAP

ECT

BLK/YELBLK/LT GRN

DR GRN/ORN

BLK/WHT

PNK/DK GRN

BLK/LT GRNTAN/WHT

LT GREENLT GRN/RED

YEL/GRYBLK/LT GRN

12V RELAYED POWERAUX ANA PD1VS-VS+AUX DIG 3AUX DIG 2GOV SELECT 1GOV SELECT 2AUX ANA PU1

AUX PWM 2GROUNDTACH

SRPNMLKJHGFEDCBA

AUX ANA PU1

AUX PWM 5AUX PWM 5 RECIRCAUX PWM 1

5V EXT 2 (FPP2 ONLY)5V RTN 2CAN1 -CAN1 +5V EXT 15V RTN 1FPP1FPP2/1VSFUEL SELECT (AUX DIG)

START IN (INTERRUPT TYPE)START IN (AUTOCRANKING)FUEL PUMP +

SRPNMLKJHGFEDCBA

MIL

FUEL PUMP -ALT EXCITEVSW

ANA RTN5V REFPC TXPC RXUNUSEDUNUSEDCAN +CAN1 -

12345678

DIAGNOSTICCONNECTOR

CONNECTOR 1

CONNECTOR 2

VEHICLE INTERFACE CONNECTORS

GROUND

OIL PRESS.SWITCH

DCBA

IGNITIONMODULE

GROUNDVBAT

UNUSEDUNUSED

CAN +CAN -1

2345678

EPRCONNECTOR

CAN +

UNUSED

BLU/WHTWHITEBLU/PNK

BLACK 16RED/LT BLU 16

F310A

F415A

F515A

F220A

F15A

MAXI FUSE

60A

ECM

IGNITION

VSW

FUEL PUMP

EPR FUSE

WHT/LT BLU 85

RED 16 30

RED/TAN 86POWER RELAY

TAN/BLK 85

PNK/YEL 16 87RED 16 30

PNK/TAN 86

FUEL PUMP RELAY

STARTERSOLENOID B

A ALTERNATORRED 16

PURPLE 16

ALTERNATOR B+RED 10

ALTERNATOR -

BLACK 10

GROUND

3087

86

85

START RELAY

87a

LT BLU/PNK 16

RED/TAN 16WHITE 16

LT BLU/PNK

PNK/BLK

RED/TAN 14 RED 14

PNK/DR GRN 16

PNK/TAN PINK

PNK/DR GRN 16 PNK/YEL 16

PNK/DR GRN 16

RED 10

RED 12

AB

TAN/DR GRNRED/BLKRED/WHTTAN/BLKTAN/REDGRY/DR BLUGRY/ORNDR BLU/YEL

LT GRN/PURLT GRN/BLKBLU/WHTBLU/PNKLT GRN/REDBLK/LT GRN

DR BLU/ORNPUR/YEL

YEL/DR BLUTAN 18BLACK 16GRAYBRN/WHT 16WHT/BRN 16

TAN 16

TAN/BRNGRN/YEL

LT BLU/PNK 16DK BLU 18PNK/YEL 16BLK/RED 16PURPLE 16PINK

BLU/WHTBLU/PNK

BLK/LT GRNLT GRN/RED

DR GRNORANGE

RED 16

B+

STARTER MOTOR

PINK/DR GRN

F615A

STARTER

RED/TAN 16 RED 16

C

SEE SHT-2FOR BATTERYCONNECTION

PNK/DR GRN 14 87

PNK/DR GRN 16

PNK/DR GRN 16

PNK/DK GRNYELLOW

BLACK 16

LT BLUE

BLACK

BLACK (12)

Figure 7-45. Electrical Schematic - Caterpillar, Deutz, & GM - with UGM - Sheet 6 of 6

1001096461 F

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

7-40 – JLG Lift – 3120740

REDBLACK

BLACKRED

PLATFORMWORK LIGHTS

ALARMMAIN TELE INMAIN TELE OUT

ROTATE RIGHTROATE LEFT

LEVEL UPLEVEL DOWN

JIB UPJIB DOWN

EMS PTF TO MTB

PTF EMSGND MODE

GND EMS

GND FROM GND MODULE

CAN LOCAN HI

START SWITCHAUX POWER

CRAB STEERCOORDINATED STEER

TOWER TELE OUTTOWER TELE IN

TOWER DOWNTOWER UP

TWO SPEEDENGINE SPEED

SOFT TOUCH OVERIDEHEAD/TAIL LIGHTS

HORN

FOOTSWITCH 2

CREEP

FUEL SELECT

GENERATOR

JIB BLOCK LIMIT SW

TILT

SYSTEM DISTRESS

FOOTSWITCH/ENABLE

CREEP

CABLE SERVICE

OVERLOAD

226KG/500# CAPACITY

453KG/1000# CAPACITY

DRIVE ORIENTATION

GENERATOR ON

GLOW PLUG

DRIVE DISABLED

PUMP POTENTIOMETER

AN

ALY

ZER

POW

ER

AN

ALY

ZER

RECE

IVE

AN

ALY

ZER

TRA

NSM

ITA

NA

LYZE

R G

ROU

ND

PLATFORM BOX

STEERLEFT

RIGHT

J1 (

WH

ITE)

SPARE ANALOG

VOLT REF.

GNDINPUT

ORN/RED 49-3

BRN/WHT 47-12

YEL/RED 2-21

ORN/RED 49-15

RED/YEL 54-2

RED/YEL 54-3

BLU/ORN 52-4-1

WHT/YEL 48-6

GRAY 23-1

GRAY 24-1PINK 25-1PINK 26-1BLUE 27-1BLUE 28-1

SWING

LIFT

DRIVE

BLU/ORN 52-12

TAN 5-1TAN 6-1

BROWN 15-1BROWN 16-1

BLUE 27-1BLUE 28-1

PINK 26-1

PINK 25-1GRAY 23-1GRAY 24-1BROWN 14-1BROWN 13-1

J2 (

GRA

Y)

J5 (

WH

ITE)

J6 (

BLA

CK)

output

PLATFORM EMS

MTBSELECTSWITCH MTB

EMS

CAN SHIELD

STROBE LIGHT

56789

1011

12

33343513

321920

2122232425181234

16172614

15

2827312930

TO B

ATTE

RY N

EG.

J8 (

BLA

CK)

J7 (

BLA

CK)

1920

333421222526

27

2829101314313032

312

23

24

8

4

176

18

79

5

15

1112

16

1

2

6

8

7

9

10

11

12

13

14

15

17

19

20

18

35

2324

22

2521

12

34

4

5

3

3332

31

30

262829

6

56

42137

Ref.VWIPER

GND

LOW FUEL LAMP

27

BLK/WHT (12)

BLU

/ORN

52-

11

YEL/

RED

2-3

(16)

YEL/RED2-2(12) ORN(12) YEL/RED

2-2(12)

RED (18)BLACK (18)SHIELD

ORANGE (18)

18 BLACK (12)

YEL/BLK(18) BLU/ORN 52-1115 15

13 13YEL/RED

2-5 ORN/BLKYEL/RED

2-5

1010

3214

3214

6 6YELLOW (18)

16

12

16

12

BLACK (12)

RED (12)

11 11BLU/BLK

BLU/ORN 52-20

WHT/YEL 48-1BRN/ORN 53-1

WHT/YEL 48-5

BLU/ORN 52-1

BRN/WHT 47-13

ORN/RED 49-4

RED (18)BLACK (18)

YEL/RED 2-3-1YEL/RED 2-30-1

BLACK (12)

YEL/RED 2-1-2

REDGREEN

WHITE

BLACK/SHIELD

4321

2

41

3

B1

B

YEL/RED 2-4 (12)

YEL/RED 2-1(12)

BLA

CK (1

0)

BLUE (18)

BROWN (18)

RED/BLK (18)

HOLE PLUG

HOLE PLUG

HOLE PLUGHOLE PLUG

YEL/

RED

2-1

-1(1

2)

5

7

9

814

1719 19

17

14

8

9

75

465

3

2

YEL/RED 2-10

RED/WHT 55-30RED/WHT 55-31

BLACK

ORN/RED 49-11

ORANGE 55-46

ORN/RED 49-40

GREENBLACK

WHITE

BLU/ORN 52-4BLU/ORN 52-3

15 AMPC.B.

YEL/

RED

2

-5-1

ORN/RED 49-100

YELLOW 55-16YELLOW 55-17

ORN/RED 49-101

BLACK

BLACK

18

TRANSPORT LENGTHSWITCH (CE ONLY)

5K

5K

5142

37

2

1

TOWER LIFT PROX. SWITCH(800 A/AJ ONLY)

BLUE

TOWER TELE. PROX. SWITCH(800 A/AJ ONLY}

WHT

TOWER ELEVATION

CAPACITY LENGTH SWITCH

CAPACITY ANGLE SWITCH

RED/ORNGREEN

BRN/BLK

ORN

/YEL

BLU

/YEL

8 7WHITEBLACK

12

ORN/RED 49-92ORN/RED 49-91ORN/RED 49-90ORN/RED 49-89

1110

9

8

WHITERED/BLUGRN/YELGREEN

BROWNBLACK OR BLU/YEL

WHT/GRNWHT/YEL

BLUERED OR WHT/REDBROWNBLACK

30

8787a

5

86 85

YEL/RED2-30-4

YEL/RED2-1-3(12)

YEL/RED 2-4 (16)

YEL/

RED

2-1

-99

(16)

IGN POWERCONNECTOR

1

CAN HIRED (18) CAN LOBLACK (18) CAN SHIELD

15 YEL/RED 2-37

BLACK

BRN/WHT 47-14

YEL/RED 2-3614

ORN/RED 49-71

ORN/RED 49-69

7ORN/RED 49-70

9ORN/RED 49-7210ORN/RED 49-7312ORN/RED 49-7511ORN/RED 49-74

YEL/RED 2-63

BLACK 7

3

4

2

1

5

6

BLAC

K 0-

1J1

-19

DUAL CAPACITYMACHINES ONLY

BLK WHT

3

4

ORN/RED 49-60ORN/RED 49-76

ORN/RED 49-62ORN/RED 49-77

123

BLACK

GREENRED

ORN/RED 49-102UPRIGHT TILTED

UPRIGHT TILT SENSORLOCATED IN UPRIGHT

WH

ITE

RED

GROUND - 4PWMY - 3PWMX - 2VCC - 1

WHITE

4

BLA

CK

YEL/

RED

2-4

2

BLA

CK 0

-8

ORN 55-50DRIVE ORIENTATIONOVERRIDE SWITCH

ORN 55-51

YEL/RED 2-63

ORN 55-52

SOFT TOUCH 16ORN/RED 49-42TO J7-35

BLACK TO SOFT TOUCH IND.35

YEL/

RED

2-9

0YE

L/RE

D 2

-75

5AMP

A B C {SE

E SHT

2 ZO

NE C

1

SEE S

HT 3,

ZON

E F7

SEE S

HT 5,

ZON

E C5

SEE S

HT 5,

ZON

E F5

SEE S

HT 6,

ZON

E F1

SEE S

HT 2,

ZONE

E6SE

E SHT

4, ZO

NE D

7SE

E SHT

5, ZO

NE E4

{

RED

1-90

5AMP

SEESHT 2

ZONE B2

YEL/

RED

2-2

0SE

E SHT

6 ZO

NE E2

NOT T

IER IV

F

ABC

X1001 X1002

SEE SHT 7ZONE H8,G8

SEE SHT 7ZONE E2

43

5612

SEE ZONE H4 BLUE 100-3

RED (18)BLACK (18)

BROWN 100-4

SEESHT 7ZONE G6

Figure 7-46. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 1 of 10

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

3120740 – JLG Lift – 7-41

AUXILIARY POWERPUMPMOTOR

M

UP LEVELDOWN LEVEL

RIGHT ROTATE LEFT ROTATE

DOWN JIBUP JIB

ALARM

MAIN TELE INMAIN TELE OUTROTATE RIGHT

ROTATE LEFT

LEVEL UPLEVEL DOWN

JIB UPJIB DOWN

PTF EMS

MTB MODE OUTPUT

START SWITCHAUX POWER/ENABLE

SWING LEFTSWING RIGHT

MAIN LIFT DOWNMAIN LIFT UP

ENGINE LOWOIL PRESSURE

ENGINE HIGHTEMPERATURE

NO CHARGE

GROUND CONTROL BOX

HOURMETER

TOWER TELE OUTTOWER TELE IN

TOWER LIFT DOWNTOWER LIFT UP

IN TOWER TELE.OUT TOWER TELE

DOWN TOWER LIFTUP TOWER LIFT

OUT MAIN TELEIN MAIN TELE

LEFT FRONT STEERRIGHT FRONT STEER

UP MAIN LIFT

DOWN MAIN LIFT

LEFT REAR STEERRIGHT REAR STEERLEFT SWINGRIGHT SWING

MAIN DUMPSTEER DUMP

FLOW CONTROL

172

10215

71223131

3133323

154

24730186

1754

16

20

9198

23333534

1021

112225

32

12

29

28

26

27

13

1

14

2

15

3

31

168

1911223534

92014

30

2729

26182428256

HEAD/TAIL LIGHT OUTPUT

FUEL SENSOR (SIGNAL)SENSOR (GROUND)

J4 (

BLUE

)

2

7

1213

21

22

24

2526

27

31302928

3233

34

35

15

32

14

29

11

30

23

28

35

32

12

6

9

10

27

20

255

8

31

MTB MODE SELECTPLATFORM MODE INPUT

23

4

1MTB EMS input

GND FROM BATTERY

GND TO PLATFORMMTB EMS TO PLATFORM

J2 (

GRAY

)

J8 (

BLAC

K)

J7 (

BLAC

K)

J1 (

WHI

TE)

248967

1314121011153

HORN OUTPUTHORN GND

BLACK 0-5

SPARE-GND

1

BLACKBLU/ORN 52-2

GRAY 23-3GRAY 24-3PINK 25-3

PINK 26-3BLUE 27-3BLUE 28-3RED/WHT 50-1YELLOW 55-2RED/WHT 50-6

BROWN 13-3BROWN 14-3YELLOW 10-1YELLOW 9-1

TAN 3-3TAN 4-3

WHITE 22-3WHITE 21-3

YELLOW 12-1YELLOW 11-1BLACK

BLACK

BLU/ORN 52-10BLACK

BRN/WHT 47-12

BRN/ORN 53-2

YEL/RED 2-40-9BROWN 13-2

BROWN 14-2GRAY 24-2GRAY 23-2PINK 25-2PINK 26-2WHT/YEL 48-1

BRN/ORN 53-2

BLUE 27-2

BLUE 28-2TAN 3-2TAN 4-2WHITE 22-2WHITE 21-2

BRN/WHT 47-8

BRN/WHT 47-5-1

BRN/WHT 47-6-1

BRN/WHT 47-8-1

BLACK

BLACK (12)

YEL/RED 2-1-2(12)

YEL/RED 2-30YEL/RED 2-2-1YEL/RED 2-30-1

YEL/RED 2-3-1

BLACKLOW FUEL LIGHTIN PLATFORM

ANALYZER POWERANALYZER RECEIVEANALYZER TRANSMITANALYZER GROUNDBLACK

1234

TAN 5-2TAN 6-2BROWN 15-2

BROWN 16-2

TAN 5-3TAN 6-3BROWN 15-3BROWN 16-3

DRIVE FORWARD3

185

6 DRIVE REVERSEORANGE 7-2

BLACKBLACK

ORANGE 8-2

2-SPEEDBRAKE

2023

ORANGE 55-47ORANGE 55-45

RED 1-2(10)

1

15

4

1411

8

10

9

19

17

16

30 AMP

2234

17

1

3

2133

19

1

3

BROWNBLACK

BROWNBLACK

BLUE

CAN SHIELDCAN LOCAN HI 13

2418

RED (18)

BLACK (18)

BLK

MAIN BOOM ELEVATION

416

726WHT

BLKWHT

BLK

YEL/RED 2-40

12

6

910

78

YEL/RED ORN/RED 49-91ORN/RED 49-90

ORN/RED 49-86

ORN/RED 49-88ORN/RED 49-87

ORN/RED 49-85ORN/RED 49-84

ORN/RED 49-934

23

56

BRN/WHT 47-15BOOM MALFUNCTION

INDICATOR

B+

12 VDCBATTERY4

4

YEL/RED 2-62ORN/RED 49-66

ORN/RED 49-65YEL/RED 2-61

BLU/ORN 52-12

8685

87

30

87a

14 GA. FUSE LINK

RED 1-1 (12)BLU/ORN 52-12ORN/RED 49-100

PLATFORMOVERLOAD

ORN/RED 49-64

WHT/YEL 48-6GLOW PLUG

WHTBLK YEL/RED 2-6012

BLACK

13

NOTE: NOT ALL BLACK GROUND WIRES ARE NUMBERED ON ALL MODELS

BLACK 0-8

ORN/RED 49-106

DRIVE ORIENTATIONPROX. SW.

321

J12

CAN HICAN LOCAN SHIELD

CDE

ABLACK

YEL/RED 2-90 HBRED 1-90

SEESHEET 2ZONE H4

DIAGNOSTICSCONNECTOR6

54

87 WHT/YEL

CLEARSKYENABLE

J3 (

BLAC

K)

BLU/ORN 52-75 13

CRIBBINGENABLESWITCH

12 YEL/RED 2-75OPTION

SEESHT 2ZONE

C6

ORN/RED 49-103

YEL/RED 2-42

BRN/WHT 47-75CRIBBING ENABLED

YEL/RED 2-21

SEESHT 3, ZONE G5SHT 5, ZONE E6

CE MARKET ONLYMDI

P/N 1001109503

BROWN 100-4

CE MARKET ONLYMSSO

SW1003

ORN 100-1

ORN 100-2

ORN

100

-2

ORN 101-1

BLUE 100-3SEE ZONE A5

Figure 7-47. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 2 of 10

1001110310 G

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

7-42 – JLG Lift – 3120740

B+ D+ W

REGULATOR

21

VEHI

CLE

INTE

RFAC

E SH

T 4 ZO

NE D

1

YEL/

RED

2-1-

99 (1

6)W

HT/Y

EL 48

-33 4 5 6

RED

CAN

HIBL

K CAN

LOBR

N/W

HT 47

-8-1

SEE

SHEE

T 2ZO

NE C5

J1-1

1 ON

SHEE

T 2 ZO

NE D

3

}SEE S

HEET

2, ZO

NE C5

SHIEL

D

14BL

U/ORN

52-5

J1-22 ON

SHEET

2ZO

NE D3

BRN/WHT 47-8-2

868587

30

87a

YEL/R

ED 2-

4-1 (1

2)TER

MINA

L BMT

B STA

TION

SELEC

T SWI

TCH

SHEET

2, ZO

NE G5

YEL/R

ED 2-

6-2

120 O

HM

BLACK

J1-10 ON

SHEET

2ZO

NE D3

BRN/

WHT 4

7-8

SEE SHEET

2ZO

NE F4

GENE

RATO

RRE

CEPT

ACLE

AB

START

ERMO

TOR

BATTE

RY +

SHEET

2ZO

NE D1

SEE VE

NDOR

SCHE

MATIC

DETA

ILSH

EET 4

ZONE

E/G2

GLOW

PLUG

S

SEE VE

NDOR

SCHE

MATIC

DETA

ILSH

EET 4

ZONE

E/G2

14 GA

FUSE

LINK

JLG

WIRI

NGFO

RCA

T ENG

INE

858630

8787a

FUELPUMP

WHT/Y

EL 48

-8

1 2

BLAC

K

J1-7

ON

SHEE

T 2, Z

ONE D

3WH

T/YEL

48-15

FUEL

PUMP

RELA

Y(LO

CATED

IN M

.T.B.)

RED 1

-2-2

BLAC

KJ1

-17 O

N SH

EET 2

, ZON

E D3

5 AM

P

BLU/O

RN 52

-5

YEL/RED 2-20

CA

B

GENE

RATO

RCO

NTRO

LBO

X

GENE

RATO

R CON

NECT

IONS A

T VE

HICLE

INTER

FACE

2SEE

SHT 6

E-1

53

YEL/

RED

2-20

868587

30

87a

BLU/

ORN

52-5

2500

WGE

NERA

TOR

POW

ERM

ITEGE

NERA

TOR

GENE

RATO

RPL

UGBA

JLG

GENE

RATO

RW

IRING

868587

30

87a

BLU/

ORN

52-5

7500

W G

ENER

ATOR

(MAC

HINE

S BEF

ORE C

N 14

7965

)

868587

30

87a

RED

5 AM

P

RED

BLU/O

RN 52

-6

YEL/RED 2-20

CA

B

GENE

RATO

RPL

UGBA

RED

BRN/

WHT

47-8

-2

7500

W G

ENER

ATOR

(MAC

HINE

S AFT

ER CN

1479

65)

5 AM

P

BLU/O

RN 52

-6

YEL/RED 2-20

CA

B

GENE

RATO

RCO

NTRO

LBO

X

GENE

RATO

RPL

UGBA

BRN/

WHT

47-8

-2

6

4000

W G

ENER

ATOR

BLU/O

RN 52

-5

BLACK

GENE

RATO

RCO

NTRO

LBO

X

GENE

RATO

RPL

UGBA

Figure 7-48. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 3 of 10

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

3120740 – JLG Lift – 7-43

PINK 1

8

DEUT

SCH_

DT06

-6S CO

NNDE

UTSC

H_04

62-20

1-161

41 TE

RMIN

ALDE

UTSC

H_W6

S LOC

KDE

UTSC

H_11

4017

CAVIT

Y PLU

G

VEHI

CLE I

NTER

FACE

RED

14

RED

8

RED

8

2 1

1AN

A RTN

EPC_

1F1T

-14A6

24-A

A-00

4 CON

NGT

S_03

30-93

0009

TERM

(18-2

9)GT

S_03

30-94

0001

TERM

(14-1

6)EP

C_E6

DB-14

A468

-DA L

OCK

EPC_

F5AB

-14A6

66-A

A CAP

DEUT

SCH_

0413

-204-2

005 P

LUG

DIAG

NOST

IC CO

NNEC

TOR1

SENS

OR O

UT2

5V RT

N

5 5V

EXT

4 DB

W -

3 DB

W +

BOSC

H GP

A-S A

CTUA

TOR

BBOSC

H_87

2-860

-521 C

ONN

BOSC

H_C-

TAB 2

99 00

4926

2 2 TE

RMIN

ALBO

SCH_

1 99 0

0 444

35 2

SEAL

OIL

PRES

SURE

DEUT

SCH_

DT06

-2S CO

NNDE

UTSC

H_04

62-20

1-161

41 TE

RMIN

ALDE

UTSC

H_W2

S LOC

K

A

AMP_

7706

80_1

CONN

ECTO

RAM

P_77

0520

_1 TE

RMIN

AL (T

IN PL

ATED

)

AMP2

3

ALT.

EXCIT

EUN

USED

STAR

TCA

N +

VSW

1 2 3 4 5 6

CAN

-

F310

A

GLOW

PLUG

S

GLOW

CONT

ROL

RED 18

BLACK

/RED 1

8

PINK/T

AN 18

RED/BL

ACK 1

8

F15A

VSW

PINK/

TAN

18PIN

K 18

DBW

+ 1

DBW

- 2ST

ARTE

R LOC

KOUT

3GL

OW CO

NTRO

L 4

SHUT

OFF

CONT

ROL

56 7 8 9

GROU

ND 1

0VB

AT 1

1TP

S 12

13OI

L PRE

SSUR

E 14 VS

W 15

5V EX

T 16

17EC

T 18

5V RT

N 19

CAN

+ 20

CAN

- 21

CRAN

K - 2

2CR

ANK +

23

PINK/

WHITE

18TA

N/OR

ANGE

18

TAN/

WHITE

18

LT GR

EEN/

RED

18

PURP

LE/LT

BLUE

18RE

D/TA

N 16

BLAC

K 16

LT BL

UE 18

PINK/

TAN

18

BLAC

K/LT

GREE

N 18

BLUE

/PIN

K 18

BLUE

/WHI

TE 18

WHITE

/PUR

PLE 1

8PU

RPLE

/WHI

TE 18

RED/

BLAC

K 18

LT BL

UE 18

BLAC

K/LT

GREE

N 18

PURP

LE/LT

GREE

N 18

BLAC

K/LT

GREE

N 18

LT GR

EEN/

RED

18

TAN/

ORAN

GE 18

PINK/

WHITE

18

TWIST

WIRES

10 TU

RNS(3

60 DE

G)/FO

OT FU

LL LEN

GTH

TWIST

WIRES

10 TU

RNS(3

60 DE

G)/FO

OT FU

LL LEN

GTH

TAN/

WHITE

18

BLAC

K/LT

GREE

N 18

ECT

PED_

1216

2193

CONN

ECTO

RPE

D_12

1240

75 TE

RMIN

AL

UNUS

EDUN

USED

UNUS

EDUN

USED

UNUS

EDUN

USED

BLUE

/PIN

K 18

BLUE

/WHI

TE 18

2 3 4 5 6 7 8

5V RE

FPC

TXPC

RXVB

ATGR

OUND

CAN1

+CA

N1 -

TWIST

WIRES

10 TU

RNS(3

60 DE

G)/FO

OT FU

LL LEN

GTH

WHITE

/PUR

PLE 1

8PU

RPLE

/WHI

TE 18

2 CR

ANK -

1 CR

ANK +

CRAN

K SEN

SOR

DEUT

SCH_

DT06

-2S CO

NNDE

UTSC

H_04

62-20

1-161

41 TE

RMIN

AL

GROU

NDBL

ACK 1

4

BLAC

K 18

13MM

RING

W/

STAR

WAS

HER

GLOW

PLUG

SOLE

NOID

5MM

RING

BLAC

K/RE

D 18

F210

A

ECM

RED/

TAN

16RE

D 16

3087

86 85

STAR

TER

RELA

Y

87a

RED

16WH

ITE 16

LT BLU

E/PINK

18

BLACK

18

STAR

TER

SOLE

NOID

STAR

TER B

+

10MM

RING

ALTE

RNAT

OR

ALTE

RNAT

OR + 7M

M RIN

G

LT BL

UE/P

INK 1

8BL

UE/P

INK 1

8BL

UE/W

HITE

18BR

OWN/

WHITE

18

RED

16

VEND

OR SC

HEMA

TICCA

T ENG

INE H

ARNE

SS

WHITE

/BLA

CK 18

BROW

N/WH

ITE 18

BROW

N/WH

ITE 18

1 2 3

UNUS

ED

18-22

GAUG

E INS

ULAT

ED BU

TT CO

NNEC

TOR

CAT 1

0731

34 CO

NNEC

TOR

GLOW

PLUG

RAIL

5MM

RING

GLOW

PLUG

SOLE

NOID

8MM

RING

RED

8

7MM

RING

WHITE

16

12 5 43

SHUT

OFF

RELA

Y

RED 18

BLACK

/WHIT

E 18

PINK/T

AN 18

WHITE

/BLAC

K 18

12 5 43F4

10A

SHUT

OFF

BK/W

18

TYCO_

172128

-1 CON

NECT

ORTYC

O_636

48-1 T

ERMINA

L

SHUT

OFF S

OLEN

OID

ENGI

NE CO

NNEC

TOR

SEE S

HT3 F

-8

Figure 7-49. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 4 of 10

1001110310 G

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

7-44 – JLG Lift – 3120740

B+ FUSIBLELINK

RECTIFER

REGULATOR

ALTERNATOR

STATOR

SENSING ANDSWITCHINGCIRCUITS

WHT

/YEL

48-

12(1

2)

J1-12

IN HEAD GLOW PLUGS

D+

sol.sol.

J1-8

J1-11

RED

1-1(

10)

STARTERMOTORSOL.

STARTER MOTOR

BRN/

WHT

47-

8-1

BLA

CK

(16)

WHT

/YEL

48-

3

BATT

ERY

CABL

E (1

GA.)

WHT

/YEL

48-

911

ORN

/RED

49-

198

1

2

10

11

12

13

14MTB

TO EM

R2 EN

GINE

CON

TROL

ORN

/RED

49-

199

BLA

CK

0-1

K

DEUTZDIANOSTICSPLUG

ENGINE OILPRESSURE

COOLANTTEMPERATURE

EMRACTUATOR

ENGINESPEEDCAMSHAFT

CHARGE AIRPRESSURE

8

9

1312

2342524

222120

14151719

GRD (SPEED)SPEED

GRD(TempAll)

GRD (ACD2)ADC5(TEMP1)+5Vref(ADC2)ADC2

+5Vref(ADC4)ADC4GND (ADC4)

ActorOutActorOutRackMeasCom

RackMeasRef18RackMeasSignal

ADC7(TEMP3) EMR2 ENGINE CONTROL TO ENGINE

YEL/

RED

2-1

-98

YEL/

RED

2-1

-99-

1

CA

N H

IRE

D (1

8)

CA

N L

OBL

AC

K (1

8)

CA

N S

HIE

LD

ABC86 85

87

30

87a

YEL/RED 2-4-1 (12) TERMINAL BMTB STATION

SELECT SWITCHSHEET 2, ZONE G5

YEL/

RED

2-6

-2

J1-10ON

SHEET 2ZONE D3

21

2

1

1234

123

12345

120 OHMRESISTOR

WHT/YEL 48-13 (8)

BRN/WHT 47-8

BLA

CK

DEUTZ EMR2 ENGINE

{

BLU/ORN 52-5

J1-22ON

SHEET 2ZONE D3

BRN/WHT 47-8-2GENERATORRECEPTACLE

A

B

BRN/WHT 47-8-1

SEESHEET 2ZONE F4

{SEESHEET 2

ZONE D3

YEL/

RED

2-1

-99

SEE

SHEE

T 2,

ZO

NE

E3

Figure 7-50. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 5 of 10

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

3120740 – JLG Lift – 7-45

LK

ENGINECONNECTOR

YEL/RED 2-1-99 (16)

WHT/YEL 48-3

MNPR

RED CAN HIBLK CAN LO

BRN/WHT 47-8-1

SEESHEET 2ZONE C5

J1-11 ON SHEET 2 ZONE D3

}SEE SHEET 2, ZONE C5SHIELD

14 BLU/ORN 52-5

J1-22ON

SHEET 2ZONE D3

BRN

/WH

T 47

-8-2

86 85

87

30

87aYEL/RED 2-6-2

BLAC

KJ1-10ON

SHEET 2ZONE D3

BRN/WHT 47-8

SEESHEET 2ZONE F4

GENERATORRECEPTACLE

A B

JLG SCHEMATICFOR

GM/PSI ENGINE

FUELPUMP

S

WHT/YEL 48-8BLACK

YEL/

RED

2-4

-1 (1

2)

TERMINAL BMTB STATION

SELECT SWITCHSHEET 2, ZONE G5

JHGFEDCBA

Figure 7-51. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 6 of 10

1001110310 G

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

7-46 – JLG Lift – 3120740

ECM-J1

K [J1]

2.5MM (1-6)

1.5MM (7,29,51,73)

1.5MM (7,29,51,73)

1.5MM (7,29,51,73)

1.5MM (7,29,51,73)

ECM CONNECTOR

12

3

4

5

6

789

10111213141516171819202122232425262728293031323334353637383940414243

4546474849505152535455565758596061626364656667686970717273747576777879808182838485868788899091929394

44

NC

ECM-J2

A [J2]

ECM CONNECTOR

1

2

3

456

789

101112131415

16

17

18

19202122232425262728293031

32

33

343536

37

38

39

404142434445

46

47

48

495051

5253

54

555657585960

EIC

EIC (ENGINE INTERFACE CONNECTION)

1

2

345678

9

1011

12

1314

15

16

1718

1920

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

3738

39

4041

42

43444546

4748

4950

5152

53545556

57

58

59

60

61

62

BLK 248-28 COOLING TEMPERATURE 0.75mm²

BLK 248-40 AIR INLET TEMP 0.75mm² BLK 248-40 AIR INLET TEMP 0.75mm²BLK 148-56 AIR INLET TEMP 0.75mm²

BLK 148-56 AIR INLET TEMP 0.75mm²

BLK 248-27 BOOST PRESSURE / TEMP 0.75mm²

BLK 248-24 BOOST PRESSURE / TEMP 0.75mm²

BLK 248-43 OIL PRESSURE 0.75mm²BLK 248-44 OIL PRESSURE 0.75mm²

BLK 248-29 OIL PRESSURE 0.75mm²

BLK 148-61 FUEL LOW PRESSURE 0.75mm²

BLK 148-61 FUEL LOW PRESSURE 0.75mm²

BLK 248-33 INJECTOR 1 1.5mm²BLK 248-16 INJECTOR 1 1.5mm²BLK 248-48 INJECTOR 4 1.5mm²BLK 248-18 INJECTOR 4 1.5mm²BLK 248-32 INJECTOR 3 1.5mm²BLK 248-2 INJECTOR 3 1.5mm²

BLK 248-46 INJECTOR 2 1.5mm²BLK 248-3 INJECTOR 2 1.5mm²

BLK 248-5 MPROP ACTUATOR 1.5mm²BLK 248-4 MPROP ACTUATOR 1.5mm²

BLK 248-25 RAIL PRESSURE FUEL 0.75mm²BLK 248-26 RAIL PRESSURE FUEL 0.75mm²

BLK 248-7 RAIL PRESSURE FUEL 0.75mm²

BLK 248-37 ENGINE SPEED CAMSHAFT 0.75mm²BLK 248-52 ENGINE SPEED CAMSHAFT 0.75mm²

BLK 248-39 ENGINE SPEED CRANKSHAFT 0.75mm²BLK 248-54 ENGINE SPEED CRANKSHAFT 0.75mm²

SHLD 248-38 ENGINE SPEED CRANKSHAFT 0.75mm²

BLK 148-38 THROTTLE FLAP 4 0.75mm²

BLK 148-38 THROTTLE FLAP 4 0.75mm²

BLK 148-72 THROTTLE FLAP 3 0.75mm²

BLK 148-72 THROTTLE FLAP 3 0.75mm²

BLK 248-20 EHXAUST GAS RECIRCULATION 1.5mm²BLK 248-19 EHXAUST GAS RECIRCULATION 1.5mm²

BLK 148-85 EHXAUST GAS RECIRCULATION 0.75mm²

BLK 148-85 EHXAUST GAS RECIRCULATION 0.75mm²

BLK 148-82 EHXAUST GAS RECIRCULATION 0.75mm²

BLK 148-82 EHXAUST GAS RECIRCULATION 0.75mm²

BLK 148-44 EHXAUST GAS RECIRCULATION 0.75mm²

BLK 148-44 EHXAUST GAS RECIRCULATION 0.75mm²

BLK 248-35 GLOW RELAY CONTROL GND 0.75mm²

(BLUE)BUSSMANN DIODE PACK

10A5A

MS9

32

B A C D E F G H

ORG

248-

23-1

GLO

W SE

NSE 1

8AW

GBL

K 24

8-23

GLO

W SE

NSE 0

.75m

m²

BLK 248-23 GLOW SENSE 0.75mm²

BLK 148-13 COOLANT LEVEL SIG 0.75mm²

BLK 148-87 COOLANT LEVEL GND 0.75mm²

BLK 148-26 FUEL PUMP RELAY CONTROL GND 0.75mm²

BLK 148-64 WATER IN FUEL SW 0.75mm²

BLK 148-57 WATER IN FUEL SW RTN 0.75mm²

RED 148-3 ECM PWR 2.5mm² S944

RED 148-1 ECM PWR 2.5mm²

RED 148-5 ECM PWR 2.5mm²

BLK 148-4 ECM GND 2.5mm² S945 BLK 148-2 ECM GND 2.5mm²

BLK 148-6 ECM GND 2.5mm²

YEL 2

-48-

1 IG

NITI

ON 1

6AW

GYE

L 2-1

-99

IGNI

TION

18A

WG

BLK 148-29 COOLANT LEVEL PWR 0.75mm²

S946

BLK 148-88 IGNITION 0.75mm²

SHLD CAN 1 SHLD CUSTOMER CAN SHIELD

S951

S9

52

S953

YEL CAN 1 HI CUSTOMER CAN HIGH

S954

GRN CAN 1 LO CUSTOMER CAN LOW

X955 ABC

YEL CAN 1 HI CUSTOMER CAN HIGHGRN CAN 1 LO CUSTOMER CAN LOW

X956

ABC

120 OHM

GRN CAN 2 LO DIAG CAN LOW

YEL CAN 2 HI DIAG CAN HIGH

SHLD 248-53 ENGINE SPEED CAMSHAFT 0.75mm²

BLK 148-15-68 CLUTCH SWITCH

BLK 148-15-68 CLUTCH SWITCH

X965 ABC

X966

ABC

120 OHM

S969

YEL CAN 2 HI DIAG CAN HIGH

S968

GRN CAN 2 LO DIAG CAN LOW

BLK 148-28 START RELAY CONTROL GND 0.75mm²

BLK 148-73 START RELAY IGN 0.75mm²

BLK 148-35-2 START 0.75mm²

Figure 7-52. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 7 of 10

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

3120740 – JLG Lift – 7-47

21

VEHICLEINTERFACE 1

WHT/YEL 48-33456

RED CAN HIBLK CAN LOBRN/WHT 47-8

J1-11 ON SHEET 2, ZONE D3

} SEE SHEET 2, ZONE C5SHIELD

J1-32 ON SHEET 2, ZONE C3

21

VEHICLEINTERFACE 2

3456

87

BLACKSEE SHEET 2, ZONE E5YEL/RED 2-20(16)

BLU/ORG 52-5 J1-22 ON SHEET 2, ZONE D3

YEL/RED 2-1-99(16) J1-10 ON SHEET 2, ZONE D3

87 30 86 85

PWR

SIG

GND

FUEL PUMPM

WATER IN FUEL

DEUTZ DIAGNOSTIC

VEHICLE INTERFACE 1

VEHICLE INTERFACE 2

M

M

VSW

START

CAN + (HI)

CAN - (LOW)

ALT EXCITE

CAN SHIELD

EMR4 IGNITION

GROUND

GENERATOR ENABLE

GLOW

GENERATOR POWER

GENERATOR GROUND

PLUGGED

PLUGGED

DEUTZ PROVIDED

START RELAY

BATTERY

POSITIVE

T920

GND

3/8" 6 AWG RING

2 x 5mm 14 AWG RING1

X901123456

ALTERNATOR

GENERICGENERIC

B+ L W

EC24

1-B+ 1

EC24

1-L 1

EC24

1-W 1

RED 47-8 ALT EXCITE 16AWGRE

D 47

-8 A

LT EX

CITE

16AW

G

RED

- - 4A

WG

X923

1

150A

RELAY, POWER MODULEGENERIC

YELLOW CONNECTORFUEL PUMP 20A (SW), ECM 30A (CONT)

BUSB

AR

BUSB

AR

BUSB

AR

BUSBAR

RL93

0-B+ 1

RL93

0-1 1

RL93

0-2 1

RL93

0 1 2

GLOWPLUG SOLENOID150 AMP

RL93

1-87 1

RL93

1-30 1

RL93

1-86 1

RL93

1-85 1

BLK 2

48-3

5 GLO

W RE

LAY C

ONTR

OL G

ND 0.

75m

m²

GLOWPLUGS

EC18

1 2

RED

48-1

3 GLO

W 8A

WG

RED

48-1

3 GLO

W 8A

WG

ORG

248-

23-1

GLO

W SE

NSE 1

8AW

G

COOL

ANT L

EVEL

NORM

ALLY

CLO

SEDSN939

2

13

4

BLK 148-13 COOLANT LEVEL SIG 0.75mm²BLK 148-87 COOLANT LEVEL GND 0.75mm²

BLK 1

48-2

6 FUE

L PUM

P REL

AY C

ONTR

OL G

ND 0.

75m

m²

X941 1234

X942 1234

BLK 148-64 WATER IN FUEL SW 16AWGBLK 148-57 WATER IN FUEL SW RTN 16AWG

BLK 148-64 WATER IN FUEL SW 0.75mm²BLK 148-57 WATER IN FUEL SW RTN 0.75mm²

RED

1-14

8-13

5 ECM

PWR 8

AWG

BLK 000-148-246 ECM GND 8AWG

BLK 148-35-1 START 18AWG

YEL 2-1-99 IGNITION 18AWG

BLK 148-29 COOLANT LEVEL PWR 0.75mm²

YEL 2

-48-

4 IGN

ITION

18AW

G

YEL 2

-48-

3 IGN

ITION

18AW

G

WHT

48-9

6 FUE

L PUM

P 14A

WG

WHT 48-96 FUEL PUMP 14AWG

BLK 000-48-1 ENG GND 14AWG

BLK 000-48-1 ENG GND 14AWGWHT 48-96 FUEL PUMP 14AWGBLK 000-48-1 ENG GND 14AWG

150A

X950 ABCDEFGHJKLM

YEL CAN 1 HI CUSTOMER CAN HIGHGRN CAN 1 LO CUSTOMER CAN LO

SHLD CAN 1 SHLD CUSTOMER CAN SHIELD

GRN CAN 1 LO CUSTOMER CAN LO

YEL CAN 1 HI CUSTOMER CAN HIGH

FUEL

PUM

P

EC958

12

WIF

SWITC

H

SN959

12

YEL 2-48-2 IGNITION

BLK 000-48-2 ENG GND

BLK 000-48-2 ENG GND

X960 ABC

X961

ABC

120 OHM

S963 GRN CAN 2 LO DIAG CAN LOW

S964 YEL CAN 2 HI DIAG CAN HIGH

GRN CAN 2 LO DIAG CAN LOWYEL CAN 2 HI DIAG CAN HIGH

X902 12345678

GENE

RIC

GENE

RIC

EC971-B+1

EC971 1

EC971-B-1

RL93

1-87

1

RL974 12

FUEL

PUM

P

EC958-1

EC958+1

X958A 12

WHT 48-96 FUEL PUMP

BLK 000-48-1 ENG GND

RL93

1-87 1

RED

48-1

4 GLO

W 8A

WG

RED

48-1

4 GLO

W 8A

WG

RED

- - 2/

0AW

G

RED

- - 2/

0AW

G

BLK 148-28 START RELAY CONTROL GND 0.75mm²BLK 148-73 START RELAY IGN 0.75mm²

X999 12

X1000 12

S1001

BLK 148-35-3 -

BLK 000-48-3 GND

BLK 000-48-3 GND

1.5 k

Figure 7-53. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 8 of 101001110310 G

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

7-48 – JLG Lift – 3120740

YEL/

RED

P3

YEL/

RED

P3

YEL/

RED

P1

YEL/

RED

P1

X500

1234

WH

T

WH

TBL

KBL

K

PLAT

FORM

SEN

SOR

18 o

hm 2

5WR5

01

YEL/

RED

P10

YEL/

RED

P2

ORN

/RED

P4

ORN

/RED

P4

ORN

/RED

P5

ORN

/RED

P5

YEL/

RED

P9-

1

YEL/

RED

P9-

1

ORN

/RED

P5-

1

ORN

/RED

P5-

1

ORN

/RED

P4-

1

ORN

/RED

P4-

1

YEL/

RED

P9

YEL/

RED

P9

BLK

P6

87 30 87a

85 86

RELAY, 12V

RL50

2-87 1

RL50

2-30 1

RL50

2-87

A1

RL50

2-85 1

RL50

2-86

1

87 30 87a

85 86

RELAY, 12V

RL50

3-87 1

RL50

3-30

1

RL50

3-87

A1

RL50

3-85 1

RL50

3-86 1

SEE

SHT

2ZO

NE

H8

YEL/

RED

P1

1363SE

ESH

T 2

ZON

E E6

PLAT

FORM

SEN

SOR

ZON

E D

6

YEL/

RED

P8

YEL/

RED

P9

ZON

E D

6

SOFT

TOU

CH

BLK

R13

4

SEE

SHT

2ZO

NE

E6

SOFT

TO

UCH

AN

D P

LATF

ORM

SEN

SOR

YEL/

RED

P9

ZON

E D

6

YEL/

RED

P2

ZON

E E2

YEL/

RED

P2

ZON

E E2

YEL/

RED

P1

3ZO

NE

D6

BLK

WH

TL

65

BLK

PLAT

FORM

SEN

SOR

SEE

SHT

2ZO

NE

E7

(FO

R PA

SSIV

E SY

STEM

, REM

OVE

PL

ATFO

RM S

ENSO

R AN

D 2

REL

AYS)

PARK

ER S

ENSO

R

1 2 3 4

BLK-

2S2 S1 S4 S3

YEL/

RED

-1

BLK-

3RE

D-4

P-J812

P-J8

A

12

X4

CAB

X5

CAB

YEL/

RED

-6

YEL/

RED

-6

BLK-

8

BLK-

8

YEL/

RED

-7

BLK-

9

BLK-

10

RED

-5

BLK-

12

RED

-11

BLK-

2

YEL/

RED

-1

BLK-

3

RED

-4

BLK-

2YE

L/RE

D-7

LOW

TEM

PERA

TURE

CU

TOU

T O

PTIO

N

LTC

OPT

ION

BO

OM

HAR

NES

S

CON

NEC

T TO

J8SH

T 2

ZON

E E-

7

MO

LEX

0428

16-0

212

CON

NEC

T TO

P8

(MAT

ING

CO

NN

ECTO

R O

F J8

)SH

T 2

ZON

E E-

7M

OLE

X

CON

NEC

T TO

X10

01SH

T 2

ZON

E F-

6

0428

18-0

212

DEU

TSCH

JLG

PN

446

0536

DEU

TSCH

JLG

PN

446

0539CO

NN

ECT

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1002

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X3

X2

Figure 7-54. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 9 of 10

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

3120740 – JLG Lift – 7-49

Figure 7-55. Electrical Schematic - Caterpillar, Deutz, & GM - without UGM - Sheet 10 of 101001110310 G

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SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS

7-50 – JLG Lift – 3120740

NOTES:

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3120740

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Discount-Equipment.com is your online resource for quality parts & equipment. Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101

Need parts? Click on this link: http://www.discount-equipment.com/category/5443-parts/ and choose one of the options to help get the right parts and equipment you are looking for. Please have the machine model and serial number available in order to help us get you the correct parts. If you don’t find the part on the website or on once of the online manuals, please fill out the request form and one of our experienced staff members will get back to you with a quote for the right part that your machine needs.

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